Automated Design of Honeycomb Conformal Cooling Channels for Improving Injection Molding Quality

Abstract

The study of conformal cooling channel usually has adopted two assumptions in model design: the use of (1) a hot runner system and (2) a one-mold-one-cavity design. These assumptions substantially simplify the research. However, most molds are designed using a cold runner system and multiple cavities. These two assumptions may not apply to all commercial systems; hence, a design method for honeycomb CCCs for cold runner systems and multiple cavities is proposed in this study. Specifically, an algorithm was developed to automatically design CCCs for such systems. This algorithm can be used to reduce the cooling time, improve product quality, and ensure that the system temperature is relatively homogenous in practical situations. According to the result of this study, the honeycomb CCC models were more effective at maintaining a homogeneous temperature distribution, reducing shrinkage, and reducing warpage for both parts produced from the same two-cavity mold, thus ensuring consistent part quality.

Comparison of Additively Manufactured Polymer-Ceramic Parts Obtained via Different Technologies

“…Using AM technologies in ceramic components production offers new possibilities and can significantly alleviate the issues encountered with conventional manufacturing methods. Additionally, an AM approach allows for the production of complex geometries [ 7 ], which is very difficult in conventional production processes, especially in the case of ceramics. In most cases, ceramic AM materials are available in the form of composites consisting of ceramic particles and an organic, polymeric matrix [ 8 ].…”